Chain Link and Method for Forming Chain Link

ABSTRACT

Chain links and methods for forming chain links are provided. A method may include inserting a pin into a pin hole defined in a boss insert, and introducing the boss insert to a mold cavity defined in a mold plate of a mold assembly. The method further includes flowing chain link substrate to the mold cavity, and cooling the chain link substrate such that a chain link is formed. The chain link includes a base portion, a platform extending from the base portion, and a rib assembly extending from the platform and including a plurality of ribs and defining a central pocket. The boss insert is disposed in the pocket, and the pin is disposed in the pin hole of the boss insert.

TECHNICAL FIELD

The present disclosure relates generally to chain links for conveyorchain, and more particularly to particularly formed chain links andmethods for forming such chain links.

BACKGROUND

Conveyor belts and chains are utilized in a wide variety of applicantsfor numerous purposes. Many conveyor chains include a plurality of chainlinks which are linked together to form the conveyor chain. Such linksand conveyor chains generally must be capable of supporting a load whichis transmitted along and by the conveyor chain.

One specific application of such conveyor chains is in poultryprocessing lines. Typically, poultry carcasses are supported on aconveyor chainin a production line on which the carcasses are debonedand/or otherwise processed. U.S. Pat. No. 7,278,536, entitled “Moldedplastic conveyor chain member for processing poultry” and which isincorporated by reference herein in its entirety, provides one exampleof a conveyor chain and the various links utilized with such belt forpoultry processing applications. In particular, the '536 patent providesvarious spaced apart links in the conveyor chain which are capable ofsupporting rods therein. Poultry carcasses are mounted on the rods forprocessing. These links of the '536 patent are entirely integrallyformed of plastic in order to be lightweight and efficient.

However, such links have various disadvantages. For example, the rodssupported by such links are typically formed from a metal such asstainless steel. The interaction between the different materials of themetal rod and plastic link may cause damage to the plastic link, thusweakening the connection between the link and rod. Further, such linksformed entirely of plastic may generally be relatively unstable,

Accordingly, improved chain links and methods for forming such chainlinks would be advantageous. In particular, chain links that arerelatively stable and which facilitate improved connections with metalrods coupled thereto would be desired, and methods which provide suchchain links would additionally be desired.

SUMMARY

Aspects and advantages of the invention will be set forth in part in thefollowing description, or may be obvious from the description, or may belearned through practice of the invention.

In one embodiment, the present disclosure is directed to a chain link.The chain link includes a base portion, a platform extending from thebase portion, and a rib assembly extending from the platform. The ribassembly includes a plurality of ribs disposed in an annular array and atube from which the ribs extend, the tube defining a central pocket. Thechain link further includes a boss insert disposed in the centralpocket, the boss insert comprising an insert body defining a centralbore, the insert body comprising an inner wall and an outer wall, theinner wall defining the central bore.

In another embodiment, the present disclosure is directed to a methodfor forming a chain link. The method includes inserting a pin into a pinhole defined in a boss insert, and introducing the boss insert to a moldcavity defined in a mold plate of a mold assembly. The method furtherincludes flowing chain link substrate to the mold cavity, and coolingthe chain link substrate such that a chain link is formed. The chainlink includes a base portion, a platform extending from the baseportion, and a rib assembly extending from the platform and including aplurality of ribs and defining a central pocket. The boss insert isdisposed in the pocket, and the pin is disposed in the pin hole of theboss insert.

In another embodiment, the present disclosure is directed to a methodfor forming a chain link. The method includes flowing chain linksubstrate to a mold cavity defined in a mold plate of a mold assembly,and flowing chain link substrate to a pin mold cavity defined in themold plate. The method further includes cooling the chain link substratesuch that a chain link is formed. The chain link includes a baseportion, a platform extending from the base portion, and a rib assemblyextending from the platform and including a plurality of ribs anddefining a central pocket. The method further includes cooling the chainlink substrate such that a pin is formed, the pin insertable into a pinhole defined in a boss insert.

These and other features, aspects and advantages of the presentinvention will become better understood with reference to the followingdescription and appended claims. The accompanying drawings, which areincorporated in and constitute a part of this specification, illustrateembodiments of the invention and, together with the description, serveto explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including thebest mode thereof, directed to one of ordinary skill in the art, is setforth in the specification, which makes reference to the appendedfigures, in which:

FIG. 1 is a perspective view of a portion of a conveyor chain inaccordance with one embodiment of the present disclosure;

FIG. 2 is a perspective assembled view of a chain link for a conveyorchain in accordance with one embodiment of the present disclosure;

FIG. 3 is a perspective exploded view of a chain link for a conveyorchain in accordance with one embodiment of the present disclosure;

FIG. 4 is a perspective cutaway view of a portion of a chain link for aconveyor chain, illustrating an interaction between a bore insert,associated pins and a rib assembly of the chain link, in accordance withone embodiment of the present disclosure;

FIG. 5 is another perspective assembled view of a chain link for aconveyor chain in accordance with one embodiment of the presentdisclosure;

FIG. 6 is a side view of a pin for use with a chain link in accordancewith one embodiment of the present disclosure;

FIG. 7 is a perspective view of a first mold plate of a mold assemblyfor forming a chain link in accordance with one embodiment of thepresent disclosure;

FIG. 8 is a cross-sectional view of a mold assembly, including a firstmold plate and a second mold plate, for forming a chain link inaccordance with one embodiment of the present disclosure; and

FIG. 9 is a perspective view of a chain link and a plurality ofsubsequent pins in a first mold plate of a mold assembly for forming achain link in accordance with one embodiment of the present disclosure.

DETAILED DESCRIPTION

Reference now will be made in detail to embodiments of the invention,one or more examples of which are illustrated in the drawings. Eachexample is provided by way of explanation of the invention, notlimitation of the invention. In fact, it will be apparent to thoseskilled in the art that various modifications and variations can be madein the present invention without departing from the scope or spirit ofthe invention. For instance, features illustrated or described as partof one embodiment can be used with another embodiment to yield a stillfurther embodiment. Thus, it is intended that the present inventioncovers such modifications and variations as come within the scope of theappended claims and their equivalents.

In general, the present disclosure is directed to chain links forconveyor chains, and in particular to distinctly designed chain linksfor conveyor chains utilized in poultry processing applications. Suchdistinctly designed chain links are provided at intervals in a conveyorchain, between normally designed chain links. The distinct chain linksof the present disclosure are generally designed to support rods whichare coupled thereto, and on which poultry carcasses may be mounted forprocessing. Further, distinct chain links according to the presentdisclosure advantageously include inserts which provide improvedstability and improved rod connections. Additionally, pins or stop nutsmay be utilized to couple the inserts to the remainder of the distinctlydesigned chain links. The pins, as well as related methods for formingsuch chain links, may facilitate excellent connection between an insertand associated remainder of a distinctly designed chain link,particularly in cases wherein the insert is formed from a materialdifferent from the remainder of a distinctly designed chain link.

FIG. 1 illustrates a portion of an exemplary conveyor chain 10. Conveyorchain includes a plurality of normal chain links 12. Such links 12 arecoupled successively to one another by pins 14 which are retained inholes 16 defined in the links 12, as illustrated. A chain according tothe present disclosure may be designed to travel in a generally straightdirection around a loop, or around a radius, or in any other suitabledirection,

As further illustrated in FIG. 1, distinctly designed chain links 20 arealso utilized in conveyor chain 10. Such chain links 20 are placed atintervals between normal chain links 12. A chain link 20 according tothe present disclosure may include abuse portion 22, which may forexample be similar or identical to at least a portion of normal chainlinks 12. Such base portion 22 may thus couple with links 12, such asthrough use of pins 14 retained in holes 24 defined in the base.

Additionally, one or more drain holes 29 (see FIGS. 2, 3 and 5) may bedefined in the base portion 22, and may for example extend laterallytherethrough, through which fluids may drain during operation. Suchdrain holes 29 may be defined during initial forming of the chain link20, such as during a molding process, or may be defined in the chainlink 20 after initial forming by, for example, drilling the drain holes29 into the base portion 22.

Referring now to FIG. 1 as well as FIGS. 2 through 5, a chain link 20according to the present disclosure may include various other componentsextending from the base portion 22. For example, a platform 26 mayextend, such as generally vertically, from the base portion 22. Platform26 may include, for example, generally laterally-extending ledges orflanges 28 which may engage in wear strip slots (not shown) along bothsides of the conveyor chain 10, to provide stability against tippingduring travel and operations to be conducted.

Further, a rib assembly 30 may extend, such as generally vertically,from the platform 26. Rib assembly 30 may include various features tostabilize and support a rod (not shown), such as a stainless steel rod,coupled to the chain link 20 for poultry processing applications. Forexample, rib assembly 30 may include a tube 32 which defines a centralpocket 34. Rib assembly 30 may further include a plurality of ribs 36extending from the tube 32, such as generally radially from the tube 32.Ribs 36 may be disposed in a generally annular array and may generallystabilize tube 32, in which a rod may be provided. Tube 32 may have aninner surface 38 which generally defines the central pocket 34. Theinner surface 38 may, for example, be generally smooth, or have atexture that corresponds to the texture of the outer surface of aninsert provided in the central pocket 34, as discussed below. Inparticular, the inner surface 38 may not include threads, such as innerfemale threads, defined thereon.

In exemplary embodiments, such variously described components of thechain link 20 may be integral. For example, the base portion 22,platform 26, and rib assembly 30 may be integral, and integrally formedutilizing for example a suitable molding technique. For example, and asdiscussed in particular below, injection molding may be utilized to formchain link 20, and the base portion 22, platform 26, and rib assembly 30may be integrally formed during such injection molding. Accordingly, inexemplary embodiments, the base portion 22, platform 26, and ribassembly 30 may be formed from the same material, which may for examplebe a plastic such as a thermoplastic. Propylene and acetal are examplesof suitable materials. It should be understood, however, that thepresent disclosure is not limited to such materials, and that anysuitable material are within the scope and spirit of the presentdisclosure. Further, in some embodiments, normal chain links 12 may beformed of the same material as such components.

A chain link 20 according to the present disclosure may further includea boss insert 40. The boss insert 40 may generally be disposed in thecentral pocket 34 of the rib assembly 30, and may be configured forcoupling the rod thereto. As illustrated, boss insert 40 may include aninsert body 42, which may define a central bore 44 which may for exampleextend vertically therethrough. Insert body 42 may include an inner wall46, which may define the central bore 44, and an outer wall 48.

In exemplary embodiments as illustrated, at least a portion of innerwall 46 may be threaded, and may thus include threads 49 definedthereon. Such threads 49 may interface with mating threads (not shown)of a rod coupled to the boss insert 40 and thus the chain link 20generally.

In some embodiments, boss insert 40 may be provided in a mold formolding the chain link 20, and rib assembly 30 may be formed around theboss insert 40. In other embodiments, boss insert 40 may be insertedinto the central pocket 34 after the rib assembly 30 is formed. Further,in exemplary embodiments, boss insert 40 may be formed from a materialthat is different from the material of other components of the chainlink 20, such as the base portion 22, platform 26, and rib assembly 30.Further, boss insert 40 may in exemplary embodiments not be integralwith such components. For example, boss insert 40 may be formed from ametal, such as in exemplary embodiments stainless steel. The use ofstainless steel or another suitable metal may advantageously improve thestability of the chain link 20 in general, particularly when a rod isattached thereto, and may further facilitate improved rod connections.In some exemplary embodiments, for example, boss insert 40 and the rodto be connected thereto may be formed of the same material. It should beunderstood, however, that the present disclosure is not limited to suchmaterials, and that any suitable material are within the scope andspirit of the present disclosure.

Referring now to FIGS. 2, 4 and 6, in some embodiments a chain link 20may further include one or more pins 50 or stop nuts. Pins 50 maygenerally connect and secure boss insert 40 to the remainder of thechain link 20, such as to the rib assembly 30. Each pin 50 may thus, asillustrated, be disposed in and extend from a corresponding pin hole 52defined in boss insert 40. Each pin hole 52 may extend, such asgenerally radially, through insert body 42. Each pin hole 52 may furtherbe defined in outer wall 46 and, in some embodiments, inner body 44. Apin 50 may include a first portion disposed within pin hole 52 and asecond portion disposed exterior to the pin hole 52 and boss insert 40when the pin 50 is generally disposed in the corresponding pin hole 52.The first portion may for example be a body 54 having a maximum width(or diameter) 55. The second portion may for example be a head 56 havinga maximum width (or diameter) 57. In exemplary embodiments, the maximumwidth 57 may be greater than the maximum width 55. The width 55 andcross-sectional area and shape may allow body 54 to generally fit withinpin hole 52, while the width 57 and cross-sectional area and shape mayprevent head 56 from fitting within pin hole 52.

The portion of pins 50 extending from and exterior to respective pinholes 52, such as the heads 56, may in exemplary embodiments be coupledto rib assembly 30, such as the tube 32 thereof. For example, pins 50may be inserted in pin holes 52 before the boss insert 40 is provided ina mold for molding the chain link 20, and the rib assembly 30 may beformed around the boss insert 40 and pins 50. Further, in someembodiments, the pins 50 may be integral with the rib assembly 30. Forexample, during molding, the temperature of the pins 50 may be raisedsufficiently such that the pins 50 at least partially melt. Upon coolingof the chain link 20, pins 50 may solidify integrally with the ribassembly 30.

In some embodiments, pins 50 may be formed from the same material as therib assembly 30, as well as the base portion 22 and platform 26. Suchmaterials facilitate the melting and integrally solidifying of the pins50. In any event, pins 50 in exemplary embodiments may be formed from asuitable plastic, such as a thermoplastic. Propylene and acetal areexamples of suitable materials. It should be understood, however, thatthe present disclosure is not limited to such materials, and that anysuitable material are within the scope and spirit of the presentdisclosure.

It should be noted that FIG. 4 illustrates pins 50 integral with a ribassembly 30, and that the cross-hatching and outlining of the pins 50are merely for illustrative purposes only to illustrate the locations ofthe pins 50,

The present disclosure is further directed to methods for forming chainlinks 20. In exemplary embodiments, as discussed above, chain links 20may be formed through molding, such as injection molding. Further, andadvantageously, pin 50 for use in chain links 20 may additionally beformed during such molding. For example, subsequent pins 50′ for usewith subsequent chain links 20 may be formed simultaneously withformation of a chain link 20, which may utilize previously formed pins50, in an injection molding process.

FIGS. 7 through 9 illustrate exemplary embodiments of a mold assembly100 for forming a chain link 20 according to the present disclosure. Amethod according to the present disclosure may include, for example,inserting one or more pins 50 into respective pin holes 52 defined in aboss insert 40, as discussed above. A method may further include, forexample, introducing the boss insert 40 to a mold cavity 102 defined ina mold plate 104 of the mold assembly, as illustrated in FIG. 7. Moldplate 104 may, for example, be a lower mold plate 104, and mold assembly100 may further include an upper mold plate 106 which may include a moldcavity 108 defined therein. The mold cavities 102, 108 may togetherdefine a mold cavity for forming a chain link 20 therein when the lowerand upper mold plates 104, 106 are brought together during the moldingprocess, as illustrated in FIG. 8.

A method according to the present disclosure may further include, forexample, flowing chain link substrate 110 to the mold cavities 102, 108.For example, mold plates 104, 106 may include runners 112 definedtherein, through which substrate 110 may be flowed. Runners 112 may bein fluid communication with the cavities 102, 108, such that thesubstrate 110 may flow through runners 112 and into cavities 102, 108.Such substrate 110 in the cavities 102, 108 may surround the boss insert40 and pins 50. Further, in exemplary embodiments, the temperaturewithin the cavities 102, 108 and/or the temperature of the substrate 110may cause pins 50 to at least partially melt, as discussed above. Thus,a method according to the present disclosure may further include, forexample, melting the pins 50.

FIG. 9 illustrates a chain link 20 disposed in mold plate 104 aftersubstrate 110 has flowed to the cavities 102, 108 to form the chain link20 and the mold plate 106 has been separated from the mold plate 104. Amethod according to the present disclosure may further include, forexample, cooling the chain link substrate 110 such that a chain link 20is formed. Cooling may be performed by, for example, the ambientenvironment, or by a cooling bath of a suitable liquid, such as water.The resulting chain link 20 may include a base portion 22, platform 26,and rib assembly 30, as well as in exemplary embodiments pins 50, formedfrom chain link substrate 110. Chain link substrate 110 in exemplaryembodiments may be a suitable plastic, as discussed above with respectto the various components. Further, in exemplary embodiments asdiscussed above, pins 50 may be integral with the rib assembly 30 aftercooling of the chain link 20. Boss insert 40 may be formed from amaterial different from the chain link substrate 110 and the pins 50,such as from a suitable metal as discussed above.

Further, in some embodiments, a method according to the presentdisclosure may include flowing chain link substrate 110 to pin moldcavities 120 defined in the mold plate 104 and, optionally mold plate106. For example, runners 122, which may be in fluid communication withrunners 112, may flow a portion of the chain link substrate 110 to pinmold cavities 120, to facilitate the formation of subsequent pins 50′for use with subsequent chain links 20. A method according to thepresent disclosure may further include, for example, cooling the chainlink substrate 110 such that subsequent pins 50′ may be formed. Theflowing step and/or cooling step may in exemplary embodiments beperformed generally simultaneously with flowing chain link substrate 110to the mold cavities 102, 108 and cooling the chain link substrate 110to form a chain link 20, respectively.

Thus, subsequent pins 50′ for insertion into subsequent boss inserts 40and for use in subsequent chain links 20 can be formed during formationof a chain link 20, which in turn may utilize previously formed pins 50.The formation of such pins 50′ in such manner advantageously increasesthe efficiency of the molding process and thus results in increased yetinexpensive chain link 20 yield.

This written description uses examples to disclose the invention,including the best mode, and also to enable any person skilled in theart to practice the invention, including making and using any devices orsystems and performing any incorporated methods. The patentable scope ofthe invention is defined by the claims, and may include other examplesthat occur to those skilled in the art. Such other examples are intendedto be within the scope of the claims if they include structural elementsthat do not differ from the literal language of the claims, or if theyinclude equivalent structural elements with insubstantial differencesfrom the literal languages of the claims.

What is claimed is:
 1. A method for forming a chain link, the methodcomprising: inserting a pin into a pin hole defined in a boss insert;introducing the boss insert to a mold cavity defined in a mold plate ofa mold assembly; flowing chain link substrate to the mold cavity; andcooling the chain link substrate such that a chain link is formed, thechain link comprising a base portion, a platform extending from the baseportion, a rib assembly extending from the platform and comprising aplurality of ribs and defining a central pocket, the boss insertdisposed in the pocket, and the pin disposed in the pin hole of the bossinsert.
 2. The method of claim 1, wherein the base portion, the platformand the plurality of ribs are formed from the chain link substrate. 3.The method of claim 1, wherein the pin is formed from the chain linksubstrate.
 4. The method of claim 1, wherein the chain link substrate isa plastic.
 5. The method of claim 1, wherein the pin is formed from aplastic.
 6. The method of claim 1, wherein the boss insert is formedfrom a material different from the pin and the chain link substrate. 7.The method of claim 1, wherein the boss insert is formed from a metal.8. The method of claim 1, wherein the pin is inserted into the pin holesuch that a first portion of the pin is disposed within the pin hole anda second portion of the pin is disposed exterior to the boss insert. 9.The method of claim 8, wherein the first portion is a body and thesecond portion is a head, the head having a maximum width greater than amaximum width of the body.
 10. The method of claim 1, further comprisingmelting the pin.
 11. The method of claim 1, wherein after cooling thechain link substrate the pin is integral with the rib assembly.
 12. Themethod of claim 1, further comprising: flowing chain link substrate to apin mold cavity defined in the mold plate; cooling the chain linksubstrate such that a subsequent pin is formed.
 13. A method for forminga chain link, the method comprising: flowing chain link substrate to amold cavity defined in a mold plate of a mold d assembly; flowing chainlink substrate to a pin mold cavity defined in the mold plate; coolingthe chain link substrate such that a chain link is formed, the chainlink comprising a base portion, a platform extending from the baseportion, and a rib assembly extending from the platform and comprising aplurality of ribs and defining a central pocket; and cooling the chainlink substrate such that a pin is formed, the pin insertable into a pinhole defined in a boss insert.
 14. The method of claim 13, wherein thechain link substrate is a plastic.
 15. The method of claim 13, whereinthe boss insert is formed from a material different from the chain linksubstrate.
 16. The method of claim 13, wherein the boss insert is formedfrom a metal.
 17. The method of claim 13, wherein the pin comprises abody and a head, the head having a maximum width greater than a maximumwidth of the body.
 18. A chain link, comprising: a base portion; aplatform extending from the base portion; a rib assembly extending fromthe platform, the rib assembly comprising a plurality of ribs disposedin an annular array and a tube from which the ribs extend, the tubedefining a central pocket; and a boss insert disposed in the centralpocket, the boss insert comprising an insert body defining a centralbore, the insert body comprising an inner wall and an outer wall, theinner wall defining the central bore.
 19. The chain link of claim 18,wherein the boss insert further comprises a pin hole defined in theinsert body, and further comprising a pin disposed in the pin hole. 20.The chain link of claim 19, wherein the pin is integral with the ribassembly.
 21. The chain link of claim 18, wherein at least a portion ofthe inner wall is threaded.
 22. The chain link of claim 18, wherein theboss insert is formed from a material different from the material of thebase portion, the platform and the rib assembly.
 23. The chain link ofclaim 18, wherein the boss insert is formed from a metal,
 24. The chainlink of claim 18, wherein the base portion, the platform and the ribassembly are integral.